Pressure Regulator Flow Limiter With Mechanical Stop Backup
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Solution Overview
Problem
Conventional pressure regulators face challenges in regulating gas flow during failure modes, such as lever disconnect events, leading to uncontrolled flow and the need for oversized relief valves, which increase costs and complexity.
Innovation Solution
The pressure regulator incorporates a stem assembly with primary and secondary control members and a mechanical stop to automatically restrict flow during failure modes, reducing the need for large relief valves by limiting maximum flow capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pressure regulators are used without flow limitation during failure modes, then the regulators can maintain normal operation, but uncontrolled flow can occur leading to overpressure damage and requiring oversized relief valves
Solution Approach 1:
The patent applies preliminary action by pre-configuring a mechanical stop and secondary control member that automatically engage during failure modes to limit flow before overpressure can occur. The mechanical stop is positioned to physically prevent the control member from moving beyond a predetermined position, thereby limiting maximum flow capacity in advance of any failure condition.
Solution Approach 2:
The patent uses an intermediary mechanism (mechanical stop and secondary control member) that mediates between the primary control member and the orifice assembly. This intermediary physically intervenes to restrict flow when the primary control fails, acting as a backup that engages only under failure conditions without interfering with normal operation.
2Reliability
If a mechanical stop and secondary control member are added to restrict flow during failure modes, then flow control during failures is improved, but the device complexity increases
Solution Approach 1:
The patent merges the secondary control function directly into the stem assembly structure. The secondary control member and mechanical stop are integrated components that work together with the primary control member, eliminating the need for separate backup systems and reducing overall device complexity while maintaining dual-mode functionality.
Solution Approach 2:
The stem assembly is designed with multi-functionality, where the same stem structure serves both normal operation (via primary control member) and failure mode (via secondary control member and mechanical stop). This universal design allows a single component to perform multiple functions across different operational states, reducing the need for additional specialized components.
3Measurement precision
If the primary control member is allowed to move freely to regulate pressure, then pressure regulation precision is improved, but uncontrolled movement during failures can cause unrestricted flow
Solution Approach 1:
The mechanical stop is pre-positioned to define a maximum travel distance for the primary control member. This preliminary physical constraint ensures that even during failure modes, the control member cannot move beyond the position that would cause uncontrolled flow, while still allowing full range of motion needed for precise pressure regulation during normal operation.
Solution Approach 2:
The mechanical stop acts as an intermediary physical constraint that mediates between the primary control member's need for free movement (for precision) and the requirement to prevent uncontrolled flow. It allows the control member to move freely within safe limits while blocking movement that would cause harmful uncontrolled flow during failures.
Data Source
AI summary
A control assembly can be configured for use with a pressure regulator having a valve body defining a fluid flow path. The control assembly can include a control member, a stem, and a lever, and can be disposed within the pressure regulator to selectively control fluid flow. The control assembly can include a primary control member and a secondary control member, or a mechanical stop that can operate to restrict flow along the fluid flow path, including when the stem disconnects from the lever.